Compressor protection module

ABSTRACT

A compressor may include a shell, a terminal assembly, an electronics module, and a molded plug. The terminal assembly may engage the shell and may include an outwardly extending conductor and a terminal fence at least partially surrounding said conductor. The electronics module may include a back plate having an opening through which said terminal fence is received. The back plate may include flexible tabs and a spring element. The flexible tabs may removably engage the terminal fence. The spring element may contact the shell and bias the back plate away from the shell. The molded plug may engage the terminal fence and may engage the conductor for electrical communication between the conductor and the molded plug.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.15/099,071, filed on Apr. 14, 2016, which is a continuation of U.S.patent application Ser. No. 13/930,403, filed Jun. 28, 2013 (now U.S.Pat. No. 9,480,177), which claims the benefit and priority of IndianPatent Application No. 756MUM2013, filed Mar. 13, 2013, and U.S.Provisional Patent Application No. 61/676,581, filed Jul. 27, 2012. Theentire disclosures of each of the above applications are incorporatedherein by reference.

FIELD

The present disclosure relates to a compressor protection module.

BACKGROUND

This section provides background information related to the presentdisclosure and is not necessarily prior art.

Compressors are used in a variety of industrial and residentialapplications to circulate a working fluid within a refrigeration, heatpump, HVAC, or chiller system (generically, “climate control systems”)to provide a desired heating or cooling effect. A typical climatecontrol system may include a fluid circuit having an outdoor heatexchanger, an indoor heat exchanger, an expansion device disposedbetween the indoor and outdoor heat exchangers, and a compressorcirculating a working fluid (e.g., refrigerant or carbon dioxide)between the indoor and outdoor heat exchangers. It is desirable for thecompressor to provide consistent and efficient operation to ensure thatthe climate control system functions properly. To this end, a compressormay be operated with an associated protection and control device.

The protection and control device may monitor operating signalsgenerated by compressor or climate control system sensors and determinecompressor or climate control system operating data. For example, theprotection and control device may determine whether compressor and/orclimate control system faults have occurred. The compressor and/orclimate control system may be controlled based on this information. Theprotection and control device may provide diagnostic information to auser or service technician.

SUMMARY

This section provides a general summary of the disclosure, and is not acomprehensive disclosure of its full scope or all of its features.

In one form, the present disclosure provides an electronic device thatmay include a housing and an electronic component disposed within thehousing. The housing may include a plug configured to engage a terminalassembly extending from a compressor shell and facilitate electricalcommunication between the plug and the terminal assembly. An exteriorsurface of the housing may include one or more receptacles extendingtherethrough in electrical communication with the electronic component.

In some embodiments, the plug may include a plug body and a plurality ofresiliently flexible tabs configured to snap into engagement withcorresponding apertures in a fence of the terminal assembly. The plugbody may include a plurality of apertures configured to receiveconductor pins of the terminal assembly.

In some embodiments, the electronic component may include at least oneof a protection module, a control module and a diagnostic module.

In some embodiments, the housing may include a base and a removable cap.The cap may include a plurality of resiliently flexible tabs that snapinto engagement with the base. The removable cap may include a displaydevice in communication with the electronic component.

In some embodiments, the one or more receptacles may be in electricalcommunication with a display device disposed remotely from the housing.In some embodiments, the display device may include an interactivefeature.

In some embodiments, the housing may be adapted to selectively engage afirst cap having an integral display device and a second cap that is inelectrical communication with a remote display device.

In some embodiments, the electronic device may include a non-volatilememory device engaging the housing.

In another form, the present disclosure provides a set of componentsthat may include a base, an electronic component, a first cap and asecond cap. The base may be adapted to be mounted to a compressor andmay include a first engagement feature and a first receptacle adapted toreceive an electrical connector. The electronic component may bedisposed within the base. The first cap may include an integral displaydevice and a second engagement feature configured to engage the firstengagement feature to secure the first cap to the base. The integraldisplay device may be in communication with the electronic device whenthe first cap is engaged with the base. The second cap may include athird engagement feature configured to engage the first engagementfeature to secure the second cap to the base. The second cap may includea second receptacle providing communication between the electroniccomponent and a remote display device.

In some embodiments, only one of the first and second caps is secured tothe base at any given time and the one of the first and second caps maybe chosen based on a system-level specification.

In some embodiments, the second engagement feature may be similar oridentical in shape and size as the third engagement feature.

In some embodiments, the base may include a plug configured to engage aterminal assembly extending outward from a compressor shell forelectrical communication between the plug and the terminal assembly. Theplug may include a plug body and a plurality of resiliently flexibletabs configured to snap into engagement with corresponding apertures ina fence of the terminal assembly. The plug body may include a pluralityof apertures configured to receive conductor pins of the terminalassembly.

In some embodiments, the base may be a part of at least one of aprotection module, a control module and a diagnostic module.

In some embodiments, the second and third engagement features may beidentical to each other.

In some embodiments, the second and third engagement features mayinclude resiliently flexible tabs.

In some embodiments, the set of components may also include anon-volatile memory received in the base.

In yet another form, the present disclosure provides a method that mayinclude providing a base including an electronic component, a firstengagement feature and a first receptacle adapted to receive anelectrical connector; mounting the base to a compressor. A first cap maybe provided that includes an integral display device and a secondengagement feature configured to engage the first engagement feature tosecure the first cap to the base. The integral display device may be incommunication with the electronic device when the first cap is engagedwith the base. A second cap may be provided that includes a thirdengagement feature configured to engage the first engagement feature tosecure the second cap to the base. The second cap may include a secondreceptacle providing communication between the electronic component anda remote display device. One of the first and second caps may beselected based on a system-level specification.

In some embodiments, mounting the base to the compressor may includeconnecting a plug extending from a surface of the base with a terminalassembly extending from a shell of the compressor.

In some embodiments, mounting the base to the compressor may includeenclosing a terminal assembly of the compressor.

In some embodiments, the method may include displaying indicia ofcompressor operating conditions on one of the integral display deviceand the remote display device.

In some embodiments, the method may include mounting the remote displaydevice on a wall of a condensing unit.

In some embodiments, the method may include inserting a non-volatilememory device into the base.

In yet another form, the present disclosure provides a compressor thatmay include a shell, a terminal assembly and an electronics module. Theterminal assembly may engage the shell and may include an outwardlyextending conductor and a terminal fence at least partially surroundingthe conductor. The electronics module may include a back plate having anopening through which the terminal fence may be received. The back platemay include an engagement feature and a spring element. The engagementfeature may removably engage the terminal fence. The spring element maycontact the shell and bias the back plate away from the shell.

In some embodiments, the spring element may include a resilientlycompressible annular gasket.

In some embodiments, the annular gasket may seal against the shell andthe back plate.

In some embodiments, the spring element may include a strip integrallyformed with the back plate and bulging outward therefrom toward theshell.

In some embodiments, the terminal fence may include a plurality ofapertures. The engagement feature may include a plurality of flexibletabs having barbs engaging the apertures.

In some embodiments, the spring element may bias the barbs intoengagement with edges of the apertures.

In some embodiments, the terminal fence may be received between thetabs.

In some embodiments, the back plate may include a receptacle includingguide rails engaging a cluster block that is electrically connected tothe conductor.

In some embodiments, the receptacle may include an opening through whichthe cluster block is removably received.

In yet another form, the present disclosure provides a compressor thatmay include a shell, a terminal assembly and an electronics module. Theterminal assembly may engage the shell and may include an outwardlyextending conductor and a terminal fence at least partially surroundingthe conductor. The electronics module may include a back plate having anopening through which the terminal fence may be received. The back platemay include a receptacle and an engagement feature. The receptacle mayreceive the terminal fence and may include guide rails removablyengaging a cluster block that is electrically connected to theconductor. The engagement feature may removably engage the terminalfence.

In some embodiments, the back plate may include a spring elementcontacting the shell and biasing the back plate away from the shell.

In some embodiments, the spring element may include a resilientlycompressible annular gasket.

In some embodiments, the annular gasket may seal against the shell andthe back plate.

In some embodiments, the spring element may include a strip integrallyformed with the back plate and bulging outward therefrom toward theshell.

In some embodiments, the terminal fence may include a plurality ofapertures. The engagement feature may include a plurality of flexibletabs having barbs engaging the apertures.

In some embodiments, the spring element may bias the barbs intoengagement with edges of the apertures.

In some embodiments, the terminal fence may be received between thetabs.

In some embodiments, the back plate may include a receptacle supportingthe guide rails.

In some embodiments, the receptacle may include an opening through whichthe cluster block may be removably received.

Further areas of applicability will become apparent from the descriptionprovided herein. The description and specific examples in this summaryare intended for purposes of illustration only and are not intended tolimit the scope of the present disclosure.

DRAWINGS

The drawings described herein are for illustrative purposes only ofselected embodiments and not all possible implementations, and are notintended to limit the scope of the present disclosure.

FIG. 1 is a perspective view of a compressor having a protection moduleaccording to the principles of the present disclosure;

FIG. 2 is a partial cross-section of the compressor of FIG. 1;

FIG. 3 is a partially exploded perspective view of the protection moduleand a terminal assembly of the compressor of FIG. 1;

FIG. 4 is a perspective view of the protection module;

FIG. 5 is a cross-sectional view of the protection module and a portionof the compressor;

FIG. 6 is a perspective view of a compressor and another protectionmodule having a remote display device according to the principles of thepresent disclosure;

FIG. 7 is a partially exploded perspective view of a housing of theprotection module of FIG. 6;

FIG. 8 is a perspective view of a compressor and yet another protectionmodule having another remote display device according to the principlesof the present disclosure;

FIG. 9 is a partially exploded perspective view of a housing of theprotection module of FIG. 8;

FIG. 10 is a perspective view of a compressor having an electronicsmodule according to the principles of the present disclosure;

FIG. 11 is a partial perspective view of the compressor and a back plateof the electronics module;

FIG. 12 is a partial cross-sectional view of the compressor and the backplate;

FIG. 13 is another partial cross-sectional view of the compressor andthe back plate;

FIG. 14 is a yet another partial cross-sectional view of the compressorand the back plate;

FIG. 15 is a partial cross-sectional view of the compressor and a backplate of another electronics module according to the principles of thepresent disclosure;

FIG. 16 is a partial perspective view of the back plate of FIG. 15;

FIG. 17 is a perspective view of the compressor having anotherelectronics module according to the principles of the presentdisclosure;

FIG. 18 is a partial perspective view of the compressor and a back plateof the electronics module of FIG. 17; and

FIG. 19 is a partial cross-sectional view of the compressor and backplate of FIG. 18.

Corresponding reference numerals indicate corresponding parts throughoutthe several views of the drawings.

DETAILED DESCRIPTION

Example embodiments will now be described more fully with reference tothe accompanying drawings.

Example embodiments are provided so that this disclosure will bethorough, and will fully convey the scope to those who are skilled inthe art. Numerous specific details are set forth such as examples ofspecific components, devices, and methods, to provide a thoroughunderstanding of embodiments of the present disclosure. It will beapparent to those skilled in the art that specific details need not beemployed, that example embodiments may be embodied in many differentforms and that neither should be construed to limit the scope of thedisclosure. In some example embodiments, well-known processes,well-known device structures, and well-known technologies are notdescribed in detail.

The terminology used herein is for the purpose of describing particularexample embodiments only and is not intended to be limiting. As usedherein, the singular forms “a,” “an,” and “the” may be intended toinclude the plural forms as well, unless the context clearly indicatesotherwise. The terms “comprises,” “comprising,” “including,” and“having,” are inclusive and therefore specify the presence of statedfeatures, integers, steps, operations, elements, and/or components, butdo not preclude the presence or addition of one or more other features,integers, steps, operations, elements, components, and/or groupsthereof. The method steps, processes, and operations described hereinare not to be construed as necessarily requiring their performance inthe particular order discussed or illustrated, unless specificallyidentified as an order of performance. It is also to be understood thatadditional or alternative steps may be employed.

When an element or layer is referred to as being “on,” “engaged to,”“connected to,” or “coupled to” another element or layer, it may bedirectly on, engaged, connected or coupled to the other element orlayer, or intervening elements or layers may be present. In contrast,when an element is referred to as being “directly on,” “directly engagedto,” “directly connected to,” or “directly coupled to” another elementor layer, there may be no intervening elements or layers present. Otherwords used to describe the relationship between elements should beinterpreted in a like fashion (e.g., “between” versus “directlybetween,” “adjacent” versus “directly adjacent,” etc.). As used herein,the term “and/or” includes any and all combinations of one or more ofthe associated listed items.

Although the terms first, second, third, etc. may be used herein todescribe various elements, components, regions, layers and/or sections,these elements, components, regions, layers and/or sections should notbe limited by these terms. These terms may be only used to distinguishone element, component, region, layer or section from another region,layer or section. Terms such as “first,” “second,” and other numericalterms when used herein do not imply a sequence or order unless clearlyindicated by the context. Thus, a first element, component, region,layer or section discussed below could be termed a second element,component, region, layer or section without departing from the teachingsof the example embodiments.

Spatially relative terms, such as “inner,” “outer,” “beneath,” “below,”“lower,” “above,” “upper,” and the like, may be used herein for ease ofdescription to describe one element or feature's relationship to anotherelement(s) or feature(s) as illustrated in the figures. Spatiallyrelative terms may be intended to encompass different orientations ofthe device in use or operation in addition to the orientation depictedin the figures. For example, if the device in the figures is turnedover, elements described as “below” or “beneath” other elements orfeatures would then be oriented “above” the other elements or features.Thus, the example term “below” can encompass both an orientation ofabove and below. The device may be otherwise oriented (rotated 90degrees or at other orientations) and the spatially relative descriptorsused herein interpreted accordingly.

With reference to FIGS. 1 and 2, a compressor 10 is provided that mayinclude a hermetic shell assembly 12, a motor-driven compressionmechanism (not shown) disposed within the shell assembly 12, and aprotection module 14. The shell assembly 12 may form a compressorhousing and may include a cylindrical shell 16, an end cap 18 at anupper end thereof, and a base 20 at a lower end thereof. A band heater21 may be secured to the shell 16 near the base 20 and may be operableto warm the shell 16, oil disposed in an oil sump (not shown) within theshell assembly 12 and/or various compressor components. A suction inletfitting 22 may extend outward from the shell 16 and may receivesuction-pressure working fluid for subsequent compression by thecompression mechanism. A discharge fitting 24 may be attached to shell16 at an opening (not shown) in the end cap 18 and may receivedischarge-pressure gas from the compression mechanism. Adischarge-temperature sensor 25 may be disposed within the dischargefitting 24 or in a conduit downstream of the discharge fitting 24 andmay measure a temperature of the discharge-pressure gas therein andcommunicate the measurement to the protection module 14. The compressionmechanism could be any type of compression mechanism such as, forexample, a scroll, reciprocating, rotary or any other type ofcompression mechanism.

Referring now to FIGS. 2 and 3, a hermetic terminal assembly 28 may beattached to the shell 16 at an opening 30 (FIG. 2). The terminalassembly 28 may facilitate electrical communication among the motor (notshown) of the compressor 10 and the protection module 14 and an externalsource of electrical power (not shown). The terminal assembly 28 mayinclude a terminal body 32, a plurality of conductor pins 34, and aterminal fence 36. The terminal body 32 may be welded or otherwisesealingly disposed within the opening 30. The conductor pins 34 mayextend outward from the terminal body 32. The terminal fence 36 mayextend outward from the shell 16 and may at least partially surround theterminal body 32 and conductor pins 34. The terminal fence 36 mayinclude a plurality of apertures 38 (FIG. 3) extending therethrough.

Referring now to FIGS. 1 and 3-5, the protection module 14 may include ahousing 40 in which protection and control electronics are provided toprotect and control the compressor 10 and/or diagnose faults of thecompressor 10 and/or faults of a climate control system in which thecompressor 10 may be operating. The protection and control electronicsmay monitor operating signals generated by sensors associated with thecompressor 10 or the climate control system and determine compressor orclimate control system operating data. For example, the protection andcontrol electronics may determine an operating mode for the compressor10 and may protect the compressor 10 by limiting operation whenconditions are unfavorable.

The protection and control electronics may be of the type disclosed inassignee's commonly-owned U.S. Pat. No. 7,412,842 or 8,036,853, thedisclosures of which are incorporated herein by reference. It isunderstood, however, that other suitable systems may be used. Theprotection and control electronics may include one or more of thefollowing: an application specific integrated circuit (ASIC), anelectronic circuit, a processor (shared, dedicated, or group) and memorythat execute one or more software or firmware programs, a combinationallogic circuit, or other suitable components that provide the describedfunctionality.

The housing 40 of the protection module 14 may include a base 42 and acap 44. The base 42 may include a body 46 and first, second, third andfourth sidewalls 48, 50, 52, 54 that cooperate with the body 46 todefine a cavity 56 (FIG. 4). The body 46 may include an exterior side 58having a plurality of posts 60 (FIG. 3) extending outward therefrom. Theposts 60 may engage corresponding receptacles 62 (FIG. 5) in the cap 44to align the cap 44 relative to the base 42. Contacts (not shown) may beprovided on the cap 44 and the base 42 to provide electricalcommunication between components of the protection and controlelectronics disposed within the base 42 and components of the protectionand control electronics disposed within the cap 44.

As shown in FIGS. 4 and 5, a terminal plug 64 may be attached to orintegrally formed with an interior side 66 of the body 46. The terminalplug 64 may include a molded body 68 that house female-electricalreceptacles 70 for receiving a respective conductor pin 34 forelectrical communication therebetween. The plurality of receptacles 70are equal in number to and arranged in the identical pattern as theconductor pins 34 of the terminal assembly 28. The receptacles 70 may bein electrical communication with the protection and control electronics.The body 68 may include a plurality of resiliently flexible tabs 72 eachhaving a ramped surface 74 and an engagement surface 76. The rampedsurface 74 and the engagement surface 76 cooperate to form a generallywedge-shaped body. As shown in FIG. 5, the tabs 72 may snap intoengagement with the apertures 38 in the terminal fence 36 such that theengagement surfaces 76 abut edges of the apertures 38 to restrict orprevent removal of the terminal plug 64 from the terminal assembly 28.It will be appreciated that the terminal plug 64 may include additionalor alternative structure to secure the terminal plug 64 and base 42 tothe terminal assembly 28. In some embodiments, the terminal plug 64 mayinclude a sealing member (not shown) to facilitate a sealed relationshipbetween the terminal plug 64 and the terminal assembly 28.

As shown in FIGS. 3 and 4, the first and second sidewalls 48, 50 of thebase 42 may include curved edges 78, 80, respectively, that have aradius approximately equal to a radius of the shell 16. In this manner,the sidewalls 48, 50, 52, 54 can be in intimate contact with the shell16, and thereby enclose the terminal assembly 28 and the terminal plug64 when the terminal assembly 28 and terminal plug 64 are connected toeach other. The second sidewall 50 may also include an electricalreceptacle 82 (FIGS. 3 and 4) that receives an electrical connector 84(FIG. 1) to facilitate electrical communication between the protectionand control electronics and wires 86 (FIG. 1) and/or electricalcommunication between the wires 86 and the terminal plug 64 and terminalassembly 28. The wires 86 could be power and/or communication wires, forexample, that may be connected to a power source and/or one or morenetwork/communication devices such as, for example, a handheld computingdevice, a system controller, or other suitable communication/networkdevice.

The third sidewall 52 of the base 42 may include another electricalreceptacle 88 (FIG. 3) and a memory chip slot 90. The electricalreceptacle 88 may receive an electrical connector (not shown) tofacilitate electrical communication between the protection and controlelectronics and wires 92 (FIG. 1). The wires 92 could supply electricalpower to the band heater 21, for example.

The memory chip slot 90 may receive a non-volatile memory device 94 thatmay be in communication with the protection and control electronics andmay store information for life-cycle tracking of the compressor 10and/or the climate control system and operational data of the compressor10 and/or the climate control system collected over the life of thecompressor 10. The non-volatile memory device 94 may be a two kilobyteor four kilobyte erasable programmable read-only memory (EPROM) chip oran electrically erasable programmable read only memory (EEPROM) chip.For example, the non-volatile memory device 94 could be of the typedisclosed in assignee's commonly-owned U.S. Pat. No. 7,412,842, thedisclosure of which is hereby incorporated by reference. Other types andother sizes of memory devices may be utilized including flash memory,magnetic media, optical media, or other non-volatile memory suitable forstoring data. Additionally or alternatively, the non-volatile memorydevice 94 may operable to communicate with a remote device via a Wi-Fi,Bluetooth™ or cellular network, for example.

Additionally or alternatively, an RFID (radio-frequency identification)device may be used. The RFID device may include non-volatile memory andmay wirelessly communicate data. If an RFID device is used, thenon-volatile memory device 94 may be a wireless data communicationdevice that allows communication with the RFID device. As used herein,the term non-volatile memory is intended to refer to a memory in whichthe data content is retained when power is no longer supplied to it,such as an EPROM or EEPROM.

The third and fourth sidewalls 52, 54 of the base 42 may also includetabs 96 (FIGS. 3 and 5) each having a ramped surface 98 and anengagement surface 100. The ramped surface 98 and the engagement surface100 cooperate to form a generally wedge-shaped body. The tabs 96 mayengage the cap 44 of the housing 40 to secure the cap 44 to the base 42.

The cap 44 may include a body 102 and first, second, third and fourthsidewalls 104, 106, 108, 110. The body 102 may include a display device112 attached thereto or integrated therein. The display device 112 maybe in communication with the protection and control electronics and maydisplay diagnostic information that a service technician may read and/orinterpret when servicing or troubleshooting the compressor 10 and/or theclimate control system. As shown in FIGS. 1 and 3, the display device112 may include one or more LED's 114 and a numeric or alpha-numericdisplay screen 118. The display device 112 may display indicia ofcompressor and/or climate control system operating conditions on thescreen 118. Additionally, one of more of the LED's 114 may illuminate toindicate a particular fault or operating condition.

The second sidewall 106 may include a receptacle 120 (FIGS. 3 and 4)that receives an electrical connector 122 (FIG. 1) to facilitateelectrical communication between the protection and control electronicsand wires 124 (FIG. 1). The wires 124 could provide electrical power tothe protection module 14 and may be in communication with a thermostat(not shown), for example, and/or one or more other control devices ofthe climate control system in which the compressor 10 may beincorporated.

The fourth sidewall 110 may include additional receptacles 126, 128(FIGS. 1 and 4) that receive electrical connectors 130, 132 (FIG. 1),respectively, to facilitate electrical communication between theprotection and control electronics and wires 134, 136 (FIG. 1),respectively. The wires 134 may be in communication with thedischarge-temperature sensor 25 or any other sensor measuring acompressor or climate control system operating parameter. The wires 136could be communication output wires for providing communication betweenthe protection and control electronics and a control device, adiagnostic device and/or a remote computer or other intelligent device,for example.

As shown in FIGS. 3 and 5, the third and fourth sidewalls 108, 110 mayinclude resiliently flexible tabs 138 that snap into engagement withtabs 96 of the base 42. The flexible tabs 138 may each include a rampedsurface 140 and an engagement surface 142. The ramped surface 140 andthe engagement surface 142 cooperate to form a generally wedge-shapedbody. Each of the engagement surfaces 142 abut a corresponding one ofthe engagement surfaces 100 of the tabs 96 of the base 42, as shown inFIG. 5. The engagement surfaces 100, 142 interfere with each other tosecure the cap 44 to the base 42.

With reference to FIGS. 6 and 7, another protection module 214 isprovided that may be substantially similar to the protection module 14described above, apart from any exceptions noted below. The protectionmodule 214 may be used in conjunction with the compressor 10 and theclimate control system described above. The protection module 214 mayinclude a housing 240 and a display device 312. The housing 240 mayinclude protection and control electronics disposed therein. Thestructure and function of the housing 240, the display device 312 andprotection and control electronics may be substantially similar to thatof the housing 40, display device 112 and protection and controlelectronics, respectively, described above, apart from any exceptionsnoted below. Therefore, similar features will not be described again indetail.

Briefly, the housing 240 may include a base 242 and a cap 244. The base242 may include a terminal plug (not shown) like the terminal plug 64 toengage and communicate with the terminal assembly 28 of the compressor10. The base 242 can be substantially similar or identical to the base42. In fact, the base 42 of the protection module 14 described abovecould be used in the protection module 214 with the cap 244. The cap 244may include a body 302 and sidewalls 304, 306, 308, 310 that may besubstantially similar to the body 102 and sidewalls 104, 106, 108, 110.The cap 244 may be removably secured to the base 42 or 242 in the mannerdescribed above. That is, the cap 244 may include resiliently flexibletabs 338 that engage tabs 96, 296 of the base 42, 242.

The display device 312 may be disposed in a remote location from thehousing 240. For example, the display device 312 could be mounted to apanel or wall 313 of an outdoor unit (e.g., a condensing unit), as shownin FIG. 6. It will be appreciated that the display device 312 could bedisposed at any other location that may be accessible to a servicetechnician. Like the display device 112, the display device 312 may bein communication with the protection and control electronics and maydisplay diagnostic information that a service technician may read and/orinterpret when servicing or troubleshooting the compressor 10 and/or theclimate control system. As shown in FIG. 6, the display device 312 mayinclude one or more LED's 314, one or more communication ports 316 and anumeric or alpha-numeric display screen 318. The display device 312 maybe in communication with the protection and control electronics viawires 323 coupled to a receptacle 320 (FIG. 7) in the cap 244 or thedisplay device 312 may be in wireless communication with the protectionand control electronics. The display device 312 may display indicia ofcompressor and/or climate control system operating conditions on thescreen 318. Additionally, one or more of the LED's 314 may illuminate toindicate a particular fault or operating condition.

With reference to FIGS. 7 and 8, another protection module 414 isprovided that may be substantially similar to the protection modules 14,214 described above, apart from any exceptions noted below. Theprotection module 414 may be used in conjunction with the compressor 10and the climate control system described above. The protection module414 may include a housing 440 and a display device 512. In someembodiments, the housing 440 may include protection and controlelectronics disposed therein. In some embodiments, the display device512 may include the protection and control electronics disposed therein,and the housing 440 may house sensing and power electronics incommunication with the protection and control electronics. The structureand function of the housing 440, the display device 512 and protectionand control electronics may be generally similar to that of the housings40, 240, display devices 112, 312 and protection and controlelectronics, respectively, described above, apart from any notedexceptions noted. Therefore, similar features will not be describedagain in detail.

Briefly, the housing 440 may include a base 442 and a cap 444. The base442 can be substantially similar to the bases 42, 242. In fact, in someembodiments, the base 42 of the protection module 14 described abovecould be used in the protection module 414 with the cap 444. The cap 444may be generally similar to the cap 244. The cap 444 may be removablysecured to the base 42, 442 in the manner described above. That is, thecap 444 may include resiliently flexible tabs 538 that engage tabs 96,496 of the base 42, 442. In some embodiments, the cap 444 may be thinneror otherwise smaller than the cap 44 due to protection, control and/ordiagnostics boards being housed in the display device 512 rather than inthe cap 444.

Like the display device 312, the display device 512 may be disposedremotely from the housing 440 and may be mounted to the wall 313 of theoutdoor unit or any other suitable location. The display device 512 maybe an interactive device and may include one or more LED's 514, one ormore communication ports 516 (e.g., a network RS 485 port), analpha-numeric screen 518 and a plurality of buttons 519. The screen 518could be an LCD screen, for example. A service technician may use thebuttons 519 and screen 518 to navigate through one or more menus toretrieve and display desired information or data (e.g., compressorand/or climate control system faults or operating conditions). Thedisplay device 512 may be in communication with the electronics in thehousing 440 via wires 523 coupled to a receptacle 520 (FIG. 9) in thecap 444. In some embodiments, the display device 512 may be in wirelesscommunication with electronics in the housing 440.

As described above, the base 42 (FIGS. 1 and 3-5) can be used with anyof the protection modules 14, 214, 414. Therefore, a manufacturer ofthree different protection modules 14, 214, 414 could manufacture asingle, common base 42 for use with all three of the protection modules14, 214, 414. This reduces the number of components that themanufacturer would produce and keep in inventory in order to offeroptions of any of the various protection modules 14, 214, 414 to an enduser.

For example, the manufacturer could provide the compressor 10 with thebase 42 connected to the terminal assembly 28 and also provide two ormore of the caps 44, 244, 444 in the manufacturer's inventory. One ofthe caps 44, 244, 444 could be selected for assembly onto the base 42depending on system-level specifications (i.e., specifications for theclimate control system) or an end user's specifications and/or dependingon which of the display devices 112, 312, 512 is called for by thesystem-level specification or end user.

With reference to FIGS. 10-14, an electronics module 614 is providedthat may be used in conjunction with the compressor 10 and the climatecontrol system described above. The electronics module 614 may include ahousing 640 in which electronic components (not shown) are provided toprotect and control the compressor 10 and/or diagnose faults of thecompressor 10 and/or faults of a climate control system in which thecompressor 10 may be operating.

The housing 640 may include a base plate or back plate 642 and a cover644. The back plate 642 may include a body 646 and a receptacle 648 thatmay be integrally formed with the body 646. As shown in FIG. 13, thebody 646 may include a central portion 650 and outer portions 652. Thecentral portion 650 may be curved around a portion of an outercircumference of the shell 16 of the compressor 10. As shown in FIGS.11-13, the central portion 650 may include a spring element 654. Thespring element 654 may abut the outer circumference of the shell 16 and,when compressed, may bias the back plate 642 away from the shell 16. Thespring element 654 may be any suitable type of spring. For example, thespring element 654 could be integrally molded with the back plate 642and may include a resiliently flexible strip of material that bulgesoutward from a first side 656 (FIGS. 12 and 13) of the back plate 642.When the first side 656 of the back plate 642 is pressed against theshell 16 with sufficient force, the spring element 654 will compress orflatten and exert a biasing force urging the back plate 642 away fromthe shell 16. It will be appreciated that the back plate 642 couldinclude any other resiliently compressible member in addition to orinstead of the spring element 654 such as a coil spring, a leaf spring,and/or a compressible foam, rubber or other elastomeric member, forexample.

The outer portions 652 of the body 646 may be disposed on either side ofthe central portion 650 and may include a plurality of barbed, flexibletabs 658 (FIGS. 11, 13 and 14). The tabs 658 may snap into engagementwith the cover 644 to removably secure the cover 644 to the back plate642.

The receptacle 648 may be integrally formed with the central portion 650of the body 646 and may be disposed between spring element 654 and anupper edge 660 of the central portion 650. The receptacle 648 may be agenerally cylindrical body including an annular sidewall 662 and agenerally planar backwall 664 that cooperate to define a generallycylindrical recess 666 (FIGS. 12 and 14). The recess 666 may include anopen end 668 opposite the backwall 664. The sidewall 662 may extendoutward from a second side 670 of the back plate 642. The sidewall 662may include a plurality of flexible tabs 672 having barbs 674 (FIG. 14)extending inwardly therefrom. The tabs 672 may be flexible relative tothe rest of the sidewall 662 so that the barbs 674 may snap intoengagement with the apertures 38 of the terminal fence 36 when theterminal fence 36 is received into the recess 666, as shown in FIG. 14.In this manner, the tabs 672 may removably secure the back plate 642 tothe terminal fence 36.

An opening 676 (FIG. 11) may extend through a portion of the sidewall662 and a portion of the backwall 664. One or more apertures 678 and/orslots 680 may also be formed in the backwall 664. The opening 676 andthe one or more apertures 678 and/or slots 680 (FIG. 11) may be incommunication with the recess 666. Guide rails 682 (FIG. 14) may extendfrom the backwall 664 toward the open end 668 of the recess 666. Distalends of the guide rails 682 may include a lip 686. A stop member 688(FIG. 12) may extend between the guide rails 682.

A cluster block 690 can be inserted through the opening 676 and can bereceived between the guide rails 682 and between the lips 686 and thebackwall 664, as shown in FIG. 14. The cluster block 690 may engage theconductor pins 34 of the terminal assembly 28 when the back plate 642 isattached to the compressor 10. The cluster block 690 may electricallycouple the conductor pins 34 to corresponding electrical leads (notshown) of the electronic protection, control and/or diagnosticcomponents of the electronics module 614. The cluster block 690 may alsoelectrically isolate each of the conductor pins 34 from each other andmay restrict or prevent moisture and/or other contaminants fromcontaminating the conductor pins 34.

As described above, the spring element 654 biases the back plate 642away from the shell 16 of the compressor 10. This biasing force urgesthe barbs 674 of the tabs 672 of the receptacle 648 against edges of theapertures 38 in the terminal fence 36 of the compressor 10, therebycreating more friction between the barbs 674 and the edges of theapertures 38. This friction between the barbs 674 and the edges of theapertures 38 may provide a more secure engagement between the terminalfence 36 and the back plate 642 and inhibits or prevents inadvertentdisengagement of the back plate 642 from the terminal fence 36 due tovibration of the compressor 10, for example.

Referring now to FIGS. 15 and 16, another electronics module 714 isprovided that may be used in conjunction with the compressor 10 and theclimate control system described above. The structure and function ofthe electronics module 714 may be similar to that of the electronicsmodule 614 described above, apart from any exceptions described belowand/or shown in the figures. Therefore, similar features may not bedescribed again in detail.

Briefly, the electronics module 714 may include a housing 740 having abase plate or back plate 742 and a cover (not shown). The back plate 742may include a body 746 and a receptacle 748 that may be integrallyformed with the body 746.

The receptacle 748 may be a generally cylindrical body including anannular sidewall 762 and a generally planar backwall 764 that cooperateto define a generally cylindrical recess 766. The recess 766 may includean open end 768 opposite the backwall 764. The sidewall 762 may extendoutward from the back plate 742 and may include a plurality of flexibletabs 772 having barbs 774 extending inwardly therefrom. The tabs 772 maybe flexible relative to the rest of the sidewall 762 so that the barbs774 may snap into engagement with the apertures 38 of the terminal fence36 when the terminal fence 36 is received into the recess 766, as shownin FIG. 15. In this manner, the tabs 772 may removably secure the backplate 742 to the terminal fence 36.

An opening 776 (FIG. 16) may extend through a portion of the sidewall762 and a portion of the backwall 764. One or more slots 780 may alsoextend through the backwall 764. Guide rails 782 may extend from thebackwall 764 toward the open end 768 of the recess 766. Distal ends ofthe guide rails 782 may include a lip 786. A stop member 788 (FIG. 16)may extend between the guide rails 782.

A cluster block 790 can be inserted through the opening 776 and can bereceived between the guide rails 782 and between the lips 786 and thebackwall 764, as shown in FIG. 15. The cluster block 790 may engage theconductor pins 34 of the terminal assembly 28 when the back plate 742 isattached to the compressor 10.

As shown in FIG. 16, an annular recess 792 may be formed in the backplate 742 adjacent the open end 768 of the receptacle 748. The annularrecess 792 may surround the open end 768 and may be generally concentricwith the sidewall 762. As shown in FIG. 15, a spring element 754 may bepartially received in the annular recess 792. The spring element 754 maybe an annular body formed from a resiliently compressible polymeric orelastomeric material, such as EPDM (ethylene propylene diene monomer) orEPDM 4211N, for example.

When the back plate 742 is attached to the compressor 10, the springelement 754 may be compressed between an end 798 of the annular recess792 and the shell 16 such that the spring element 754 surrounds theterminal fence 36. In this manner, the spring element 754 may sealagainst the shell 16 and the back plate 742 to restrict or preventmoisture and/or other contaminants from seeping into the receptacle 748and/or accumulating on the terminal assembly 28. The spring element 754may also provide a biasing force that urges the back plate 742 away fromthe shell 16. As described above, this biasing force urges the barbs 774of the tabs 772 of the receptacle 748 against edges of the apertures 38in the terminal fence 36 of the compressor 10, thereby creating morefriction between the barbs 774 and the edges of the apertures 38. Thisfriction between the barbs 774 and the edges of the apertures 38 mayprovide a more secure engagement between the terminal fence 36 and theback plate 742 and inhibits or prevents inadvertent disengagement of theback plate 742 from the terminal fence 36 due to vibration of thecompressor 10, for example.

With reference to FIG. 17-19, another electronics module 814 is providedthat may be used in conjunction with the compressor 10 and the climatecontrol system described above. The electronics module 814 may include ahousing 840 in which electronic components 815 (FIG. 18) are provided toprotect and control the compressor 10 and/or diagnose faults of thecompressor 10 and/or faults of a climate control system in which thecompressor 10 may be operating.

The housing 840 may include a base plate or back plate 842 and a cover844. The electronic components 815 can be mounted to the back plate 842or the cover 844, for example. As will be subsequently described, theback plate 842 may engage the terminal fence 36 and may provideclearance for a molded plug 845 (FIG. 17) to be securely received withinthe terminal fence 36 for engagement with the conductor pins 34. Themolded plug 845 may sealingly engage an inner diameter of the terminalfence 36 and may provide electrical communication between the conductorpins 34 and the electronic components 815 and/or other control,diagnostic and/or protection electronics (not shown) located remotelyfrom the compressor 10. As shown in FIG. 17, the cover 844 may removablyengage the back plate 842 and may include sleeves 849 through whichwires 851 connected to the molded plug 845 may pass. The sleeves 849 mayprovide a sealing function to restrict water, dust and/or debris fromentering a space between the back plate 842 and the cover 844. Thesleeves 849 may also provide protection for current transformers 853(FIG. 18) that may measure electrical current passing through at leastone of the wires 851. Such current measurements may be used for theprotection, diagnostics and/or control of the compressor 10 and/or theclimate control system in which the compressor 10 may be operating.

Referring now to FIGS. 18 and 19, the back plate 842 may include a body846 having an opening 848 extending therethrough. A collar 850 mayextend outward from a first side 852 of the body 846 and may at leastpartially surround the opening 848. Flexible tabs 854 may be disposedadjacent the opening 848 and may extend outward from the first side 852.In some embodiments, the flexible tabs 854 could be integrally formedwith the collar 850. The tabs 854 may include inwardly facing barbs 856.A second side 858 of the body 846 may include an annular recess 860(FIG. 19) that may at least partially surround the opening 848. As shownin FIG. 19, an annular spring element 862 may be partially received inthe recess 860. The spring element 862 may be substantially similar tothe spring element 754, for example, and may be an annular body formedfrom a resiliently compressible polymeric or elastomeric material, suchas EPDM or EPDM 4211N, for example.

When the back plate 842 is connected to the compressor 10, the terminalfence 36 may extend through the opening 848 and the barbs 856 of thetabs 854 may snap into engagement with the apertures 38 in the terminalfence 36. When the barbs 856 are engaged with the apertures 38, thespring element 862 may surround the terminal fence 36 and may becompressed between an end 861 of the recess 860 and the shell 16. Inthis manner, the spring element 862 may seal against the shell 16 andthe back plate 842 to restrict or prevent moisture and/or othercontaminants from seeping into the opening 848 and/or accumulating onthe terminal assembly 28. The spring element 862 may also provide abiasing force that urges the back plate 842 away from the shell 16. Asdescribed above, this biasing force urges the barbs 856 of the tabs 854against the edges of the apertures 38 in the terminal fence 36 of thecompressor 10, thereby creating more friction between the barbs 856 andthe edges of the apertures 38. This friction between the barbs 856 andthe edges of the apertures 38 may provide a more secure engagementbetween the terminal fence 36 and the back plate 842 and inhibits orprevents inadvertent disengagement of the back plate 842 from theterminal fence 36 due to vibration of the compressor 10, for example.

While the spring elements 754, 862 are described above as being aresiliently compressible polymeric or elastomeric gasket, in someembodiments, the spring elements 754, 862 could be or include a coilspring or any other type of spring member. In some embodiments, the backplates 742, 842 may include a spring element similar to the springelement 654 described above in addition to or in the alternative to thespring elements 754, 862. It will be appreciated that the electronicsmodule 614 may also include a spring element and/or gasket similar tothe spring elements 754, 862.

The electronic components 815 (shown in FIG. 18) may include a pluralityof indicator assemblies 861 each having a light emitting diode (LED) 855and a light pipe 857. Each LED 855 may be an indicator of a fault code,a status of the compressor 10 or a status of the climate control system,for example. Each LED 855 may be adjacent a corresponding one of thelight pipes 857. The light pipes 857 may extend through apertures 859(FIG. 17) formed in a top end 843 of the cover 844. The light pipes 857may transmit the light from LEDs 855 to be visible from the top ofelectronics module 814. While the figures depict two indicatorassemblies 861, the electronics module 814 may include any other numberof indicator assemblies 861.

The foregoing description of the embodiments has been provided forpurposes of illustration and description. It is not intended to beexhaustive or to limit the disclosure. Individual elements or featuresof a particular embodiment are generally not limited to that particularembodiment, but, where applicable, are interchangeable and can be usedin a selected embodiment, even if not specifically shown or described.The same may also be varied in many ways. Such variations are not to beregarded as a departure from the disclosure, and all such modificationsare intended to be included within the scope of the disclosure.

What is claimed is:
 1. A compressor comprising: a shell; a terminalassembly engaging said shell and including an outwardly extendingconductor and a terminal fence at least partially surrounding saidconductor; an electronics module including a back plate having anopening through which said terminal fence is received, said back plateincluding flexible tabs and a spring element, said flexible tabsremovably engaging said terminal fence, said spring element contactingsaid shell and biasing said back plate away from said shell; and amolded plug engaging said terminal fence and engaging said conductor forelectrical communication between said conductor and said molded plug. 2.The compressor of claim 1, wherein said spring element includes aresiliently compressible annular gasket.
 3. The compressor of claim 2,wherein said annular gasket seals against said shell and said backplate.
 4. The compressor of claim 3, wherein said back plate includes anannular recess at least partially surrounding said opening, and whereinsaid annular gasket is at least partially received in said annularrecess.
 5. The compressor of claim 1, wherein said terminal fenceincludes a plurality of apertures, and said flexible tabs include barbsengaging said apertures.
 6. The compressor of claim 5, wherein saidspring element biases said barbs into engagement with edges of saidapertures.
 7. The compressor of claim 5, wherein said terminal fence isreceived between said flexible tabs.
 8. The compressor of claim 7,wherein said molded plug is received within said terminal fence.
 9. Thecompressor of claim 1, wherein said electronics module includes a coverremovably attached to said back plate, and wherein said back plate andsaid cover cooperate to form an enclosure in which a plurality ofelectronic components are disposed.
 10. The compressor of claim 9,wherein said electronics module includes one or more indicator lightsextending through one or more apertures formed in said cover.
 11. Thecompressor of claim 9, wherein said cover includes a plurality ofsleeves through which wires connected to said molded plug extend. 12.The compressor of claim 11, wherein said sleeves and said wires extendthrough current transformers disposed between said cover and said backplate.
 13. The compressor of claim 9, wherein said cover includes arecess in which said molded plug is disposed, and wherein said moldedplug is disposed outside of said enclosure formed by said back plate andsaid cover.
 14. An electronics module comprising a back plate and anelectronic component mounted to said back plate, said back plateincluding an opening receiving a terminal fence extending outward from ashell of a compressor, said back plate including flexible tabs and aspring element, said flexible tabs removably engaging said terminalfence, said spring element contacting said shell and biasing said backplate away from said shell.
 15. The electronics module of claim 14,wherein said spring element includes a resiliently compressible annulargasket that seals against said shell and said back plate.
 16. Theelectronics module of claim 15, wherein said back plate includes anannular recess at least partially surrounding said opening, and whereinsaid annular gasket is at least partially received in said annularrecess.
 17. The electronics module of claim 14, wherein said terminalfence includes a plurality of apertures, and said flexible tabs includebarbs engaging said apertures, and wherein said spring element biasessaid barbs into engagement with edges of said apertures.
 18. Theelectronics module of claim 17, wherein said terminal fence is receivedbetween said flexible tabs, and wherein a molded plug is received withinsaid terminal fence, said molded plug in electrical communication with aconductor surrounded by said terminal fence.
 19. The electronics moduleof claim 18, wherein said electronics module includes a cover removablyattached to said back plate, and wherein said back plate and said covercooperate to form an enclosure in which said electronic component isdisposed.
 20. The electronics module of claim 19, wherein said coverincludes a recess in which said molded plug is disposed, and whereinsaid molded plug is disposed outside of said enclosure formed by saidback plate and said cover.